DELIVERABLE REPORT - TRANSFORMERS deliverables...¢  public deliverable report deliverable n0: d3.4 dissemination

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    DELIVERABLE REPORT

    DELIVERABLE N0: D3.4

    DISSEMINATION LEVEL: PUBLIC (PU)

    TITLE: DEMONSTRATOR OF A MISSION ADAPTABLE HYBRID-ON-DEMAND

    DRIVELINE INSTALLED IN A TRACTOR SEMI-TRAILER VEHICLE

    DATE: 31.08.2017

    VERSION: FINAL

    AUTHOR(S): GUNTER NITZSCHE, SEBASTIAN WAGNER (FHG IVI)

    REVIEWED BY: BIRGER QUECKENSTEDT (SCB), ALFREDO SELAS (BOSCH),

    RAMANAN KARTHIK (VOLVO)

    APPROVED BY: COORDINATOR – PAUL ADAMS (VOLVO)

    GRANT AGREEMENT N0: 605170

    PROJECT TYPE: THEME 7 TRANSPORT – SST GC.SST.2012.1-5: INTEGRATION AND

    OPTIMISATION OF RANGE EXTENDERS ON ELECTRIC VEHICLES

    PROJECT ACRONYM: TRANSFORMERS

    PROJECT TITLE: CONFIGURABLE AND ADAPTABLE TRUCKS AND TRAILERS FOR

    OPTIMAL TRANSPORT EFFICIENCY

    PROJECT START DATE: 01/09/2013

    PROJECT WEBSITE: WWW.TRANSFORMERS-PROJECT.EU

    COORDINATION: VOLVO (SE)

    PROJECT MANAGEMENT: UNIRESEARCH (NL)

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    605170 – D3.4 – Demonstrator Of A Mission Adaptable Hybrid-On-Demand Driveline Installed In A Tractor Semi-Trailer Vehiclereport On Hod Driveline Running In The Trailer 2 / 24

    Executive summary

    The objective of the EU-funded project TRANSFORMERS is to design, develop, and demonstrate truck-

    trailer concepts for long-haulage applications featuring high energy efficiency. Therefore,

    TRANSFORMERS combines a modular approach for mission rightsizing by means of hybridization and

    a trailer design that addresses simultaneously aerodynamics and load efficiency improvements. The

    overall goal is to achieve a 25% higher load efficiency (in energy/km.tn) in a real world application,

    while taking the needs to maintain road infrastructure and traffic safety into account.

    A key innovation of TRANSFORMERS is the so-called Hybrid-on-Demand-Driveline (HoD-Driveline).

    For the first time, this system enables an augmentation of conventionally driven trucks and tractors to

    fully functional mission-adaptable hybrid vehicles, simply by coupling them to an innovative trailer

    equipped with an electric driveline. Hence, the HoD-Driveline concept is applicable to many kinds of

    truck-trailer combinations.

    In addition to the HoD-Driveline concept TRANSFORMERS has developed a pre-standardisation HoD-

    Framework document. The objective of this framework is:

     to ensure the interoperability of the HoD-Driveline concept with today’s and with future trucks

    featuring advanced energy management capabilities,

     to provide a slim common interface between trucks and trailers, that requires only minimal

    changes to the existing standard interface.

    Deliverable D3.21 describes a first holistic draft of the pre-standardisation Hybrid-on-Demand

    Framework document including:

     Specification of the logical and E/E-architecture of the HoD-Driveline,

     Specification of the necessary interfaces, and

     Specification of the functions of affected electronic control units.

    This deliverable summarizes the key findings regarding the HoD framework in Chapter 5.2 including

    the lessons learned during demonstrator implementation and real world testing. Throughout the

    whole development process, the HoD-Framework was continuously refined. Primarily, the changes

    affected the interfaces defined in D3.2. Several signals were added, e.g. due to safety and optional

    man-machine interface requirements.

    Based on the HoD framework specifications deliverable D3.4 shows that the HoD system is

    successfully integrated and running in a truck-semitrailer vehicle. The key achievements reported in

    this deliverable are:

     Electric driveline tested in the trailer,

     Successful overall commissioning of HoD semitrailer with two trucks proving interoperability,

     Proof of technical feasibility of the initial technical approach, and

     Proof of the applicability of the HoD Framework.

    1 Access to D3.1 and D3.2 or parts of it can be granted upon request. Please contact the project

    coordinator. It is currently under discussion to make D3.2 available via EUCAR.

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    Contents

    Contents .............................................................................................................................. 3

    List of Acronyms ................................................................................................................... 4

    1 Introduction ................................................................................................................... 5

    1.1 Scope ..................................................................................................................... 5

    1.2 Context ................................................................................................................... 6

    1.3 Technical background / system overview ..................................................................... 6

    2 Overall HoD Framework System Architecture ...................................................................... 7

    2.1 ECU Functionalities ................................................................................................... 7

    2.1.1 VCU .................................................................................................................... 7

    2.1.2 TDMS .................................................................................................................. 8

    2.1.3 TEBS ................................................................................................................... 8

    2.1.4 EMG-ECU ............................................................................................................. 9

    2.1.5 ESU-ECU .............................................................................................................. 9

    2.2 HoD Interfaces ......................................................................................................... 9

    3 Demonstrator driveline ................................................................................................... 10

    3.1 TDMS .................................................................................................................... 11

    3.2 Self-contained ESU .................................................................................................. 11

    3.3 EMG and EMG inverter ............................................................................................. 12

    3.4 Gearbox with integrated Clutch ................................................................................. 12

    4 Commissioning and Test Results ...................................................................................... 13

    4.1 Clutch operation ...................................................................................................... 15

    4.2 Brake blending ........................................................................................................ 16

    4.3 On-road testing ....................................................................................................... 17

    5 Conclusions ................................................................................................................... 20

    5.1 General Findings ..................................................................................................... 20

    5.2 HoD-Framework ...................................................................................................... 22

    5.3 Lessons Learnt ........................................................................................................ 23

    6 Acknowledgment ........................................................................................................... 24

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    List of Acronyms

    Akronym Description

    ABS Anti-lock Braking System

    ASR see TCS

    CC Cruise Control

    DA Destination Address

    EBS Electronic Braking System

    EBSI Electronic Braking System Interface

    ECU Electronic Control Unit

    EMG Electric Motor Generator of the trailer

    EMGI Electric Motor Generator Interface

    ESU Energy Storage Unit of the trailer

    ESUI Energy Storage Unit Interface

    HoD Hybrid-on-Demand

    HoDD Hybrid-on-Demand-Driveline

    HoDF Hybrid-on-Demand-Framework

    HV High Voltage

    ICE Internal Combustion Engine

    LV Low Voltage

    MMI Man Machine Interface

    PDU Protocol Data Unit (see e.g. ISO 11992 Part 3)

    PF PDU Format

    PS PDU Specific

    PTO Power Take-Off

    PTCH Positive Temperature Coefficient Heater

    RCP Rapid Control Prototyping

    SA Source Address

    SLOT Scaling, Limit, Offset and Transfer function definitions in J1939

    TCS Traction Control System

    TDMS Trailer Driveline Management System

    TEBS Trailer Electronic Braking System

    TEMS Trailer Energy M